ultratech cement limited unit: rawan cement works …
TRANSCRIPT
Welcome to CII
22nd National Award for Excellence in
Energy Management 2021
Team Members:1. Mr. Shriprakash Gupta- (Sr. Gen. Manager & Energy Auditor)
2. Mr. Pawan Potghan – (Manager Operation)
3. Mr. Raghvendra Mishra – (Sr. Engineer & Energy Auditor)
UltraTech Cement LimitedUnit: Rawan Cement Works-Captive Power Plant
UltraTech Cement Ltd - Rawan Cement Works
▪ UTCL : A part of ABG which is the bestemployer in India and Asia Pacific region.
▪ Rawan Cement Works : An Unit of UTCL
▪ 55 MW capacity Captive Power Plant
(25 + 30)
▪ 15.18 MW capacity WHRS unit.
▪ 10.8MW Solar Power Plant.
▪ Fullest compliance to Environment Norms.
▪ Certified with ISO 9001, 14001, OHSAS
18001, ISO 27001, SA8000 standards &
Excellence in Energy Efficient.
▪ Adopted World Class Manufacturing
Excellence Model.
Rawan Cement Works
Company Profile
▪ Safe shutdown of plant & Asset preservation effectively.
▪ Safe restoration of the plant post lockdown (1st May’20 onwards.)
▪ Sustained continuous & reliable operation of TPP/WHRS.
▪ Practicing “Doing more with less” to optimize the productivity.
▪ “Idea generation” through brainstorming within team.
❑ Plant operation continuity during Covid-19 scenario :
❑“Vajra” at TPP & WHRS
❖ “Vajra” structure implemented at TPP & WHRS in line with cluster
guidelines to protect business continuity.
❖ Total 04 groups created for ensuing continuity of plant operation. (No
overlap of any member)
❖ Total 31 “Vajras” created covering TPP & WHRS out of these four groups.
Business Continuity plan against Covid-19: RWCW TPP
Project
Precautionary practices against Covid-19 Avoiding hand
Process Flow Diagram
30993085 3043
2018-19 2019-20 2020-21
8.78.3 7.7
2018-19 2019-20 2020-21
4.22
4.65
4.30
2018-19 2019-20 2020-21
Due to High fuel cost
78.175.2
69.1
2018-19 2019-20 2020-21
Key Performance Indicators - TPP
PLF (%) Heat Rate (Kcal/Kwh)
Auxiliary Power (%) Power Cost (Rs./Kwh)
GO
OD
GO
OD
GO
OD
GO
OD
GOOD
7.00 %5.50 %
3.98%
2018-19 2019-20 2020-21
Key Performance Indicators - WHRS
11.7
12.713.1
2018-19 2019-20 2020-21
WHRS AVG Generation (MWH) GO
OD
95.2106.2
94.8
2018-19 2019-20 2020-21
Generation (Million Kwh)
Decreased due to Low
clicker production (COVID-19)
33.6 34.840.5
2018-19 2019-20 2020-21
AQC-2 HP Steam Generation (TPH)
GO
OD False Air Reduction
GO
OD
GO
OD
Plant Performance Benchmarking With UTCL Units
2973 3011 30423098 3101 3103 3121 3137 3153 3154 3162 3166
3228 32413287 3309
3371 3393 3403 3420
GK01 VC01 GC01 DL01 GW01 MN01 AC01 HC01 BN01 SR01 RC01 AP01 BL01 SG01 AW01 SD01 MA01 RP01 BW01 GS01
Plant Heat Rate (Kcal/KWh) FY-21Rawan TPP (3rd)
7.08 7.33 7.54 7.60 7.67 7.72 7.95 7.968.47 8.55 8.68 8.74 8.77 8.97
9.41 9.59 9.60
VC01 SR01 GK01 AP01 GC01 MA01 AW01 GW01 AC01 GS01 SD01 MN01 HC01 SG01 BN01 RP01 RC01
Aux. Power Consumption (%) FY-21Rawan TPP (5th)
Reduction in Energy Consumption. 1. Reduction in TPP Heat Rate.2. Reduction in Auxiliary Power Consumption.3. Plant Reliability by monitoring R1/S1& R2/S2 and Condition Based Monitoring.
Reduction in Fix Cost 1. Man Power Optimization. 2. PR/PO Cost reduct.
Reduction in Power Mix Cost 1. WHRS Generation enhancement by 4.0 MW.2. HAR System in Line-23. Reduction in TPP Fuel Cost by using Low-Cost Fuel & AFR.4. TG # 2 Major Overhauling .5. Optimization – Optimax Operation
“ FOCUS AREA = FUEL COST +FIXED COST+ ENERGY CONSERVATION + DIGITALISATION ”
TARGETPower Mix Cost Fuel Cost Aux. Cons.
Rs. 3.18 Rs/KWH Rs. 4.07 Rs/KWH 7.18 %
Safety
Team Focus Area and Target
Safety –
Zero Harm
Maximize WHRS Power
TPP APC & PHR
Reduction
Low Cost fuel
utilisation
Fix Cost Reduction
Zero Break down
Saving 1425.32 Lac/Annum
Platforms for Improvement Opportunity
Brain Storming Sessions
Strategic Meeting for suggestion
Suggestion Funneling
KPI’s review meeting
Gap Analysis Meeting
Team Action Plan Review Meeting
Safety Action plan Meeting
Daily coordination Meeting
Priority Qty.Saving
( Rs-Lacs)
P1 43 504
P2 42 921.32
P3 3 0
Total 1425.32
P1 : Easy to Implement, No cost Involved, high business impact.P2 : Slight Modification , Legal Permission and cost involved.P3 : Moderate business Impact.
Engage to Excel – Team of Teams
Team Work, Emp. Involvement & Monitoring Difficult to implement with less Business Impact and High Cost Involved
Store & Spares and Repair & Maintenance
Some how difficult, required shutdown, Cost and high business Impact (Priority-P3)
Easy to Implement with slight modification by use of internal resources in less cost with high Business Impact (Priority- P2)
Easy to Implement, No cost Involved with high Business impact & reliability improved (Priority-P1)
20%
40%
60%
100%
80%
Qty Saving Rs.
10 9 Rs. Lac
Qty Saving Rs.
03 0 Rs. Lac
Qty Saving Rs.
43 504 Rs. Lac
Qty Saving
41 921.32 Rs. Lac
Qty Saving
14 107.65
Total Suggestions87 Nos.
Projected Saving Rs. 1425.32 Lacs
Priority /CostArea Of Suggestion
TotalCost Involvement
QtyNo Cost Target Date Cost benefit
KPI Improvement Safety WCM Relaibility
P1 22 6 11 4 43 26 17 31.03.2022 504.0 Rs. Lac
P2 21 2 9 9 41 20 21 30.03.2022 921.32 Rs. Lac
P3 3 1 1 1 3 1 2 31.10.2021 0 Rs. Lac
Funneling of Suggestions
0
200
400
600
FY 18 FY 19 FY 20 FY 21
352410
425
510
Kaizens/Suggestions Implemented
Team Work & Employee Involvement
Nos.
Identified of 2 Best Six sigma Project from suggestion list and cross functional team formation done for execution of project.
1
People skill development through on the job training , learning from other units and presentation on technical topics.
2
Promote TPP Paathshala & Margdarshan program to increase the technical knowledge of employee.
3
Focus of multiskilling to reduce the BSR cost and effective utilization of manpower.
4
Conducting in- house classroom training program to improve the knowledge of employee on safety, behavioral and functional skills.
5
Major Initiative for People and Team Development
SNFinancial
Year
Investment/
No Investment
No. of
Projects
Electrical Energy
(MWH)
Heat Energy
Savings
(TOE/Year)
Savings in
Rs. Million
Invested
Amount in
Rs. Million
1 2020-21No Investment 15 2236 798 17.25
5.9Investment 4 1280 521 7.02
2 2019-20No Investment 13 1820 756 3.63
12.2
Investment 9 1280 480 13.8
3 2018-19No Investment 17 1528 760 17.25
6.5Investment 5 761 450 7.02
Total 59 8905 3765 65.9 24.6
Details of Energy Saving Projects
TOTAL SAVED ENERGY- 4649 TOE
Major Energy Conservation Projects 2020-21
Sr.
No.Energy Saving Tasks
Annual Energy SavingsSavings
(Rs million
/Annum)
Electrical
(kWh)
Thermal
Energy
TOE/Year
1.Reduction in Plant Heat Rate by 20 Kcal/kwh through Fine tuning of
Auto process controller in TPP-2. (Optimization of Dump loss)NIL 333 3.1
2.
Reduction in Auxiliary power consumption in Boiler Fans by 580
Kwh/day through Fine tuning of Auto process controller in TPP-2.
(Optimization of oxygen in furnace.)
191400 NIL 0.62
3.Reduction in Plant Heat Rate by 12 Kcal/Kwh by Hydrojet cleaning
in TPP-1 ACC.NIL 166 1.5
4. Reduction of TPP fuel cost by 0.02 Rs/Kwh by Use of Alternate Fuel
in Boiler. (10% by mass).NIL NIL 6.5
5. Reduction of TPP Plant heat rate by 60 Kcal/Kwh by the usage of
surplus WHRS steam to TPP.NIL 1098 10.2
6. Reduction in Aux. power consumption by 1500 Kwh/Day in TPP-1
ACC Fans by high pressure Hydrojet cleaning of chocked fin tubes.495000 NIL 1.61
7. Reduction in Aux. power consumption by 800 Kwh/Day in TPP-2 ACC
Fans by high pressure Hydrojet cleaning of chocked fin tubes.264000 NIL 0.86
8.Reduction in TPP-2 Boiler Feed Pump Auxiliary Power Consumption
by replacement of attemperator nozzle to reduce DP of 1.5 Kg/cm2.179520 NIL 0.583
Major Energy Conservation Projects 2020-21
Sr.
No.Energy Saving Tasks
Annual Energy Savings Savings
(Rs.
million
/Annum)
Electrical
(kWh)
Thermal
Energy
TOE/Year
10.Reduction in TPP-2 Boiler Feed Pump Auxiliary Power Consumption by 480
Kwh/Day through major Overhauling of pump by KSB.138600 NIL 0.450
11.Reduction in WHRS ACC Fan power by replacement of existing blade with new
energy efficient blades.158400 NIL 0.515
12.
Reduction in Compressor Auxiliary Power Consumption by reducing Compressor
SPC reduced from 4.37 to 3.20 through operational philosophy and Loss
correction.
169620 NIL 0.551
13.Reduction in TPP Boiler Fans Auxiliary Power Consumption by reducing SPC from
19.72 to 17.6 through removal of suction dampers and False air reduction.246840 NIL 0.802
14. Optimization of CHP power consumption. 99000 NIL 0.322
15. Connected HPH-1 drain line with LPH to reduce Plant Heat Rate by 6 KCal/Kwh. 0 100 0.9
16. Optimized the windbox pressure from 950 to 850 mmWC @PLF <65%. 99000 NIL 0.322
Total 2041380 1696 28.82
TOTAL SAVED ENERGY- 1872 TOE
Major Energy Conservation Projects 2019-20
Sr.
No.Energy Saving Tasks
Annual Energy Savings Savings
(Rs million
/Annum)
Electrical
(kWh)
Thermal Energy
(TOE/Year)1 Reduction of TPP Plant heat rate by the usage of surplus WHRS steam to TPP. 122500 1098 11.38
2Reduction in specific power consumption of K-Pump from 4.0 to 3.0 Kwh/MT
by proper air balancing to the system.70000 NIL 0.32
3 Reduction in BFP Power consumption by further DP Logic modif. as Per load. 87500 NIL 0.39
4 Reduction of false air from 5.5 % to 3.3%. 73500 NIL 0.33
5
Reduction of Specific power consumption of Boiler Fans Power from 21.47 to
19.95 Kwh/Mw by taking the corrective action on Air slide system of MDC
System (i.e. ash recirculation system of Boiler).295556 NIL 1.33
6 Optimization of lighting power consumption. 11771 NIL 0.05
7
Reduction of compressor Power by optimizing the air consumption in ash
handling system by implementation of in-house logic for ash handling system
as per load.46278 NIL 0.21
8Reduction in specific power consumption of AC from 3.63 to 2.67 Kwh/MW by
installing the AC controller (6Nos.)186200 NIL 0.84
9 Line-2 ESP Power consumption reduction from 500 Kwh to 300 Kwh/Day 70000 132 0.32
10Reduction in TPP Fly ash LOI from 2.35 to 2.10 % by implementation of MDC
RAV Logic with Bed temperature.NIL 389 1.31
11 Wind box pressure reduced to 1040 from 1250 in Boiler-2. 196000 NIL 4.74
Total 4186199 1619 21.2
TOTAL SAVED ENERGY- 1719 TOE
Major Energy Conservation Projects 2018-19
Sr.
No.Energy Saving Tasks
Annual Energy Savings Savings
(Rs million
/Annum)
Electrical
(kWh)
Thermal Energy
(TOE/Year)
1 Auto Operation of Dump steam in Line-2 Nil 259 2.22
2 DM water Consumption reduced from 40 to 16 M3 in Line-2 Nil 481 4.12
3 TPP Fly ash LOI reduction from 3 to 2% Nil 880 7.54
4 Line-2 ESP Power consumption reduction from 2000 Kwh to 950 Kwh/Day 339465 NIL 1.43
5 AC Power Reduction. 285797 NIL 1.21
6 Compressor Power Consumption Reduction in Line-2. 161650 NIL 0.68
7 K -pump Power consumption reduction. 276748 NIL 1.17
8Line-1 ESP Power consumption reduction from 1940 Kwh/Day to 550
Kwh/Day.172916 NIL 0.73
9Line-2 ESP Power consumption reduction from 930 Kwh/Day to 500
Kwh/Day.139019 NIL 0.59
10 Optimization of lighting power Cons. 47450 NIL 0.20
11PA air temp increase 7 Deg C by replacing APH tube in PA path in line-2
(150 Nos.).Nil 92 0.78
12 BFP Auto DP logic implemented as per looking Load MW in Line2. 484950 NIL 2.05
Total 1907995 1612 22.72
TOTAL SAVED ENERGY- 1712 TOE
Machine
High Power Consumption
Breakdown
Compressors BFP, ACW
DCS logic
AVR trippingBoiler tube
Idle running CHP Belts
Over-running CT fan
ACC fanSA / PA fan
Method
Combustion
efficiencyLoad variation
Operation
Inadequate Control
Parameters
Fuel feed
Pressure & flow
High Power
Consumption
Crusher
Operation
Maintenance
Scheduling
& planning
Spares QualityMisalignment
Work
quality
Manpower
Services
Over times
AMC charges
Fatigue
Health
Abilities
ExperienceSkills
Behaviour at
work
Concentration
Attitude
Occupational disease
Frequent
start ups
Heat loss
& Air
leakage
SOPs &
logic
Material
Fuel
Carpet stock System Leakage
Transportation
Over charging
High GCVUneven
Storage
Bed material
Delivery
Drain losses
Fly ash & Bed ash LOI
Electricity dues
Statutory
duesCess
Sampling
Training
Appliances
External
service
Error &
fault
Probes & gauges
Causing Factors
Analysis: Key Factors Causing High Power Consumption
Innovative Projects & Implementation – Aux. Power
Innovative Projects & Implementation
Design of Experiment(DOE)
Solution
Benefit
Reduction in TPP-2 Auxiliary Power Consumption by digitization of Boiler-2 through Advanced Process Controller (APC).
➢High Load variation during solar hour.➢Process Optimization through manual intervention.
➢Installation of Advanced Process Controller in TPP-2 Boiler.
➢PID Logic modifications to smoothen process operation.
➢Fine tuning of logics for process optimization.
➢Automation of Boiler Operation with less manual intervention.➢Fine tuning of Advance process controller resulted in power saving of 570 Kwh/Day in boiler Fans.➢Achieved Annual Monetary Gain of 5.64 Lacs.
Theme
Problem
Gain of Rs. 5.64 Lacs / Annum
Advanced Process Controller in TPP-2
Initiative-1 : Reduction in TPP-2 Auxiliary Power Cons. By APC
Solution
Benefit
Reduction in TPP-2 Boiler Fans Auxiliary Power Consumption.
➢False air ingress across boiler circuit was high @5.9%.➢Suction air DP was high in both SA and PA Fans due to
silencer and suction duct length.
➢Removal of suction damper of SA & ID fan.➢False air reduced from 5.9% to 2.9% .➢Reduced bed height to 850 from 900 mmwc during
load < 65%.
➢Boiler Fans SPC reduced from 19.72 to 17.6.➢Achieved Annual Monetary Gain of 11.24 Lacs.
Theme
Problem
Gain of Rs. 11.24 Lacs / Annum
25.29
19.72 18.38 18.60 18.10 17.60
FY'18-19 FY'19-20 Q1'20-21 Q2'20-21 Q3'20-21 Q4'20-21
Fans SPC (Kwh/Mwh)
Suction damper removed
Initiative-2 : Reduction in Boiler Fans Auxiliary Power Cons.
Solution
Benefit
Reduction in Compressor Auxiliary Power Consumption.
➢High bend loss in compressed air network.➢Leakages and loop holes in air circuits.
➢Auto logic for fly ash conveying w.r.t load.➢Relocation of 55 KW compressor➢Replaced bends in line with long radius (06 Nos.)➢Revised operation philosophy as.Only 55 KW comp. at load < 65% V/s. 160 KW.55 + 75 KW comp. at load > 65% V/s. 160 KW.
➢Compressor SPC reduced from 4.37 to 3.20.➢Achieved Annual Monetary Gain of 5.51 Lacs.
Theme
Problem
4.75 4.373.46 3.34 3.23 3.20
FY'18-19 FY'19-20 Q1'20-21 Q2'20-21 Q3'20-21 Q4'20-21
Compressor SPC (Kwh/MW)
Gain of Rs. 5.51 Lacs / Annum
Before Modification After Modification
Initiative-3 : Reduction in Compressor Auxiliary Power Cons.
Solution
Benefit
Reduction in TPP-2 Boiler Feed Pump Auxiliary Power Consumption.
➢Attemperation efficiency was poor due to old design.➢High pressure loss across attemperator nozzle.
➢Replaced the old nozzle with newly designed one.➢Line pressure parts and gland correction done.
➢Less DP across the nozzle during water spray.➢Reduced the BFP DP by nearly 2.0 Kg/CM2.➢Improvement in reliability of steam temperature to
Turbine-2 inlet.➢Achieved Annual Monetary Gain of 5.83 Lacs.
Theme
Problem
Gain of Rs. 5.83 Lacs / Annum
Before Modification
After Modification
24.50
22.95
21.80
22.70 22.50 22.40
FY18-19 FY19-20 Q1'21 Q2'21 Q3'21 Q4'21
BFP SPC – Kwh/MWH
Initiative-4 : Reduction in TPP-2 BFP Auxiliary Power Cons.
TPP-1 ACC Tube bundle fins cleaning through High Pressure water jet.
Due to surrounding cement dust nearby TPP ACC area, ACC tube finsgets chocked. Because of this, heat transfer effectiveness of ACCdecreases and thereby increases Aux. power consumption of ACC Fansand Turbine Heat Rate.
▪ In Foam chemical cleaning, hard scaling of tube bundles was notremoved. So there was a need to think out of box to remove hardscales. Team brain stormed, thought innovatively to use highpressure (>200Kg/cm2) water jet to remove hard scale.
▪ For Cleaning of ACC Tube fins, High Pressure hydro-jet system isused. In this, water at a pressure of 250 kg/cm2 is allowed to strikein tube bundles. As a result of this, hard scaling is removed.
➢ Achieved Aux. power saving of 1500 KW/Day in ACC Fansconsidering same TG PLF and ambient temperature.
➢ Turbine Heat Rate reduced by 10 Kcal/Kwh.
Solution
Benefit
Theme
Problem
Monetary Gain of Rs. 27.32 Lacs / Annum
Before Cleaning Bundle Condition
After Cleaning Bundle Condition
Initiative-5 : Reduction in TPP-1 ACC Aux. Power Cons. & PHR
Innovative Projects & Implementation – Heat Rate
High Plant Heat
Rate
Man
Method
Equipment
Material
Dump/start-up vent operation manually ¬ concentrate on same
High TG SSC
Low Boiler Efficiency
Plant Operate at
Low vacuum
Passing of Drain/Vent
Plant Operate at Low Main Steam Pressure &
Temp.Plant Operate at Low PLF%
High DM water
Load fluctuation & dump steam
Delay in CBD valve Closing
Plant Start stop increase
Steam trap passing condition
Steam water line drain/vent not close properly
During CBD v/v Operation, it not close properly
High LOI in Ash
Boiler operate at high excess O2
Boiler tube
APH performance
High Moisture in Fuel
High Ash Content in fuel
Feed water & Steam quality is not upto the mark
Desing Problem
Mesurement
Wrong Coal Measurement
Wrong Steam Flow Totalizer
Wrong PHR calculation
Analysis: Key Factors Causing High Plant Heat Rate
Solution
Benefit
Reduction in Heat Rate by Utilization of surplus steam of WHRS at TPP-2.
➢Earlier HP-1 Extraction steam line circuit which was connected in WHRS in a way to increase WHRS Generation was isolated due loss.
➢There was no alternate source to preheat condensate water by utilizing waste heat in TPP-2 HP-1 Heater.
➢Explored the optimum and feasible option to utilize this surplus steam above the requirement of rated capacity running of WHRS which is up to 15.18 MW. Considered its running at max. 16.0 MW load.
➢Existing circuit used for utilization of surplus WHRS steam.
➢Flow meter and Pressure transmitter correction done.
➢TPP-2 Plant Heat Rate reduced by 56 Kcal/Kwh.➢ESP Inlet flue gas temperature reduced by 12 Deg C
resulting in reduction of PHR of 10 Kcal/Kwh.➢Achieved Annual Monetary Gain of 116 Lacs.
Theme
Problem
Gain of Rs. 116 Lacs / Annum
Initiative-1:Utilization of surplus steam of WHRS to reduce TPP PHR
Solution
Benefit
Reduction in Heat Rate by Fine tuning of Auto process controller in TPP-2.
➢High Load variation during solar hour.➢Process Optimization through manual intervention.
➢Installation of Advanced Process Controller in TPP-2 Boiler.
➢PID Logic modifications to smoothen process operation.
➢Fine tuning of logics for process optimization.
➢O2 reduced by 0.60% approximately & Heat rate by 6.0 Kcal/kwh.
➢Loss reduction of dump steam by 7.4 MT/day & Heat rate by 14.0 Kcal/kwh.
➢Achieved Annual Monetary Gain of 47.0 Lacs.
Theme
Problem
Gain of Rs. 47.0 Lacs / Annum
4.253.85
3.45 3.353.733.80 3.45
2.85 2.603.18
60 % PLF 70 % PLF 80 % PLF 90 % PLF Avg 75 %PLF
Dry flue gas O2 %
Before O2% After O2%
13.616.9
12.88 14.1 14.4
9.42 9.1
5.0 4.47.0
Q1 Q2 Q3 Q4 Average
Dump steam (MT/Day)
Dump steam : FY'19-20 Dump steam : FY20-21
Initiative-2 : Heat rate reduction by Fine tuning of APC
Solution
Benefit
Reduction in Fly Ash LOI in order to improve Boiler-1&2 Efficiency.
➢Unburnt Carbon in Fly-ash was 2.4%.➢False air ingress across boiler circuit was high @6.5%.
➢Auto MDC operation as per furnace temperature.➢Fine tuning of bed height as per variable load.➢Close vigilance on bed material size and keeping shift
wise samples to CCR for prompt actions.
➢LOI reduced form 2.4% to 1.99% resulting in Gross Heat Reduction of 15 Kcal/Kwh.
➢Achieved Annual Monetary Gain of 22.45 Lacs.
Theme
Problem
Gain of Rs. 22.45 Lacs / Annum
2.392.13 2.08 2.05 1.99
FY 2019-20 Q1'20-21 Q2'20-21 Q3'20-21 Q4'20-21
Fly Ash LOI%
Monitoring of Bed material Bulk
density in every shift.
Mapping of unburnt carbon in all field
hoppers in every shift.
Optimization of Furnace Bed Height
and Combustion air at varying Load.
Thought Process
Initiative-3 : Heat rate reduction by Fly ash LOI % reduction
Green Township
❑ 10 MW Solar Power Generation Started from Feb’19
❑800 KWH Solar Panels Installed in FY 2011-12 .
❑Colony Power requirement mainly catered through Solar power generation
GO
OD
Renewable Energy Use
9.7 9.437.6
173.0156.1
16-17 17-18 18-19 19-20 20-21
Solar Power Generation
Utilization of TPP fly ash & Bed ash :
Utilisation / Recycle of Waste
▪ Bed ash as well as fly ash beinggenerated from boilers are conveyedpneumatically to silos.
▪ From Silos, fly ash is again transportedthrough dense phased closed pneumaticsystem up to cement mill silos where it isbeing consumed 100% for cementmanufacturing.
▪ Complete bed ash in storage silos isreconditioned through wet unloadingsystem and then loaded in tipper.
▪ It is being used completely as a rawmaterial for cement plant. It is added inthe raw meal additive hopper for furtherprocess at cement plant.
7096178510 73238
17740 19628 18310
8870198138
91548
18-19 19-20 20-21
Recycle of Waste (MT/Year)
Fly Ash Bed Ash Total
GHG Inventorization
250300350400450500550
2018-19 2019-20 2020-21 NationalBM
487 471
432 400
KG
CO
2/M
T O
F C
EMEN
T
Specific CO2 Emission
500
550
600
650
700
2018-19 2019-20 2020-21
691 682665
KG
CO
2/M
T O
F P
RO
DU
CT
Specific CO2 Emission
Cementitious Product Cement
* Lowest Carbon Footprints/Specific Emissions among all UltraTech plants
GO
OD
GO
OD
Best Practices in Water Management :
Environment Management - Water
▪ By Meter/Measure/Manage Methoda. Monitoring & measuring water generation &consumption on daily basis.b. Preparing the deviation report for extra waterconsumption at unit level.▪ Utilizing the boiler drain water in cooling towers.▪ Stabilizing the STPs at unit colony & factory(plant)
& using the STP water in Cooling towers.▪ Treating the influent water & using it at plant
green garden.▪ TPP SWAS drain Water is being used at P&V
system.
We are Zero Discharge Plant Are You…….???????
PAT Status (TOE/Ton of Product)
Save Energy - Save Money - Save the Planet
0.0647
0.0616
0.0598
0.0582
0.0558
0.0647
0.0566
Base Line PATCycle-2
Target SEC PATCycle -2
Actual inFY'16-17
Actual inFY'17-18
Actual inFY'18-19
Actual inFY'19-20
Actual inFY'20-21
GOOD
Projects Implemented :
▪ Reverse logistics - Coal rake used to send Clinker to grinding Units.▪ Dedicated 132 KV line between RWCW and HCW. Later, to improver further, the PMS has
been hooked up between these two units.
Benefits Achieved :
▪ Reverse loading of rakes equals to reduction in incoming rakes and resulted in fuel saving.▪ Dedicated 132 KV line along with common PMS has helped significantly to improve
reliability of operation and plant performance parameters at both end.
Supplier Evaluation :
▪ Waste Belt Reuse/ Rebuilding▪ On the basis of sustainability factors- safety, Health & Environment.▪ Joint Improvement projects.
Green Supply Chain Management
Way Forward: Energy Saving Projects
SN Project in Pipe Line GainEnergy Saving
PotentialTarget Date
1Reduction of PHR of TPP-2 Turbine by Major overhauling of
TG-2.PHR Reduction 60 Kcal/Kwh 31.10.2021
2TPP-1 Plant heat rate reduction through condensate water
preheating from WHRS AQC-1 boiler outlet flue gas.PHR Reduction 40 Kcal/Kwh 31.08.2022
3TPP-1 APH Performance improvement by False air reduction
and De-choking & replacement of chocked tube.PHR Reduction 5 Kcal/Kwh 31.10.2021
4
Reduction of Power in TPP-2 SA Fan in Boiler-2. by
replacement of SA fan impeller with new energy efficient
(20KWH).APC Reduction 450 Kwh/Day 31.10.2021
5WHRS Power enhancement of 4MW by Modification in turbine
& boiler.Power
Enhancement4000 Kwh/Day 31.08.2022
6WHRS ACC Fan power reduction by replacement of old design
ACC Fan (4 nos) with energy efficient blades.
APC Reduction960 Kwh/Day 30.11.2021
7Reduction of Aux. power consumption in TPP-1 BFP by
modification in internal hydraulic in Pumps.
APC Reduction420 Kwh/Day
31.03.2022
Way Forward: Energy Saving Projects
SN Project in Pipe Line GainEnergy Saving
PotentialTarget Date
8Installation of Water Fog System below ACC Fans to improve
vacuum.PHR Reduction 5 Kcal/Kwh 31.10.2021
9TPP-2 ACC Fan replacement with energy efficient ENCON
blade for 8 Fan.APC Reduction 1000 Kwh/Day 31.10.2022
10 Inter-connection of TPP-1&2 Cooling tower. APC Reduction 350 Kwh/Day 31.10.2021
11
Replacement of Old Technology ACW Pumps having Pump
Efficiency (65%) with new technology high efficiency (80%)
pumps in TPP-1
APC Reduction 400 Kwh/Day 31.10.2022
12 TPP-1 Cooling Tower Fill replacement work. APC Reduction 200 Kwh/Day 30.09.2021
Total Energy Saving PotentialPHR Reduction = 110 Kcal/Kwh ≈ (1829 TOE)Aux Power Reduction = 8030 Kwh/Day ≈(265 TOE)
Total Saving Of Energy ≈(2094 TOE)
Energy Auditor/Manager
Raghvendra Mishra
Energy Auditor – EA-31223 Shriprakash B Gupta
Energy Auditor – EA 5934
P C Shekhar Rao
Energy Manager –EA 20580
Vibhav Jaiswal
Energy Manager – EM 3325Dinesh Kumar Verma
Energy Manager – EM 5121
Purushottam . K. Singh
Energy Manager – EM 16333Atulesh Lanjewar
Energy Manager – EM-7737
Energy Management Policy
Energy Policy implemented in 2009Energy Policy states unit ’s commitmenttowards continual energy performanceimprovement
Energy policy is communicated at all levels
Daily Review of Energy & PAT data w.r.t BEST
Dedicated Energy Cell with fortnightly review
Three layer Team Structure for stringent Monitoring Regular Improvement Projects
on Energy Conservation
Real time power consumption data monitoring through online Energy Monitoring System
Daily Energy Monitoring
Energy Management System
Power Generation Planning for HCW & RWCW
Energy Monitoring, Reporting & Implementation Methodology
Monitoring & Review Formats
Description Formats
Daily Co-ordination meeting on Power and Performance review
Review of Daily Power Report for any deviation
Energy Cell Meeting Points Compliance review
Energy Audit (Internal & External) Points Compliance
Energy Management Cell with clear cut responsibilities.
Daily monitoring of Energy Deviation report.
Benchmarking with National/International/Group
Units/Cluster units and action plan for improvement.
Regular study of Equipment's on deviation and their
analysis.
Process Evaluation & Identification of Energy Conservation
scope.
Feasibility study of suggestions and designing proposals for
sanctions.
Promoting energy saving idea generation by shop floor
teams and time bound implementation
Organizing Internal and External Energy Audit.
.
Certifications
SA 8000 ISO 27001ISO 9001, 14001, OHSAS 18001
Awards: Journey Towards Excellence
Rajiv Gandhi C
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20
17
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7
2008
2008
2008
2009
2011
2014
2015
2016
2017
CII 22th National Award for Excellence in Energy Management 2021
CII
19
thN
atio
nal
Aw
ard
of
Exce
llen
ce in
En
erg
y M
anag
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2018
AB
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20
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Zo
nal
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2019
CII
20
thN
atio
nal
Aw
ard
of
Exce
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fici
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nit
20
19
2019
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